RC-IGBT and manufacturing method thereof

ABSTRACT

An RC-IGBT having a transistor portion and diode portion is provided. An RC-IGBT having a transistor portion and diode portion, and including: a semiconductor substrate; drift region of the first conductivity type provided on the upper surface side of the semiconductor substrate; base region of the second conductivity type provided above the drift region; source region of the first conductivity type provided above the base region; and two or more trench portions provided passing through the source region and the base region from the upper end side of the source region is provided. The diode portion includes: a source region; contact trench provided between two adjacent trench portions of the two or more trench portions on the upper surface side of the semiconductor substrate; and contact layer of the second conductivity type provided below the contact trench, whose doping concentration is higher than a doping concentration of the base region.

The contents of the following Japanese patent application(s) are incorporated herein by reference:

NO. 2016-180024 filed in JP on Sep. 14, 2016,

NO. 2017-138181 filed in JP on Jul. 14, 2017, and

NO. PCT/JP2017/033363 filed on Sep. 14, 2017.

BACKGROUND 1. Technical Field

The present invention relates to an RC-IGBT and a manufacturing method thereof.

2. Related Art

Conventionally, it is known to provide a high concentration P type layer to extract holes between trenches (refer to Patent Document 1, for example). Also, in an RC-IGBT having a transistor portion and a diode portion, it is known to provide a diode portion with a high concentration N type layer to reduce hole implantation from an anode (refer to Patent Document 2, for example). Patent Document 1: Japanese Patent Application, Publication No. 2013-065724. Patent Document 2: Japanese Patent Application, Publication No. 2015-135954.

However, in a conventional semiconductor device, a reverse recovery characteristic of a diode portion cannot be reduced sufficiently.

SUMMARY General Disclosure

The first aspect of the present invention may provide an RC-IGBT having a transistor portion and a diode portion, the RC-IGBT including: a semiconductor substrate; a drift region of the first conductivity type provided on the upper surface side of the semiconductor substrate; a base region of the second conductivity type provided above the drift region; a source region of the first conductivity type provided above the base region; and two or more trench portions provided passing through the source region and the base region from the upper end side of the source region. The diode portion may include: source regions; contact trenches provided between two adjacent trench portions of two or more trench portions on the upper surface side of the semiconductor substrate; and contact layers of the second conductivity types provided below the contact trenches, whose doping concentrations are higher than doping concentrations of base regions.

Lower ends of the contact layers may be positioned shallower than positions of lower ends of the source regions.

The source regions may be in direct contact with the contact trenches in the diode portion.

The transistor portion may include: contact trenches provided between two adjacent trench portions of two or more trench portions on the upper surface side of the semiconductor substrate; and contact layers of the second conductivity types provided below the contact trenches of the transistor portion, whose doping concentrations are higher than doping concentrations of base regions. Widths of the contact trenches of the diode portion may be narrower than widths of the contact trenches of the transistor portion.

The contact trenches of the diode portion may have aspect ratios higher than aspect ratios of the contact trenches of the transistor portion.

Lower ends of the contact trenches of the diode portion may be positioned deeper than positions of lower ends of the contact trenches of the transistor portion.

The lower ends of the contact layers of the diode portion may be positioned shallower than positions of the lower ends of the contact layers of the transistor portion.

The number of peaks of doping concentrations in the contact layers of the diode portion may be less than the number of peaks of doping concentrations in the contact layers of the transistor portion.

The doping concentrations of the contact layers of the diode portion may be lower than the doping concentrations of the contact layers of the transistor portion.

The RC-IGBT may further include: the first accumulation region of the first conductivity type having a doping concentration higher than a doping concentration of the drift region; and the second accumulation region of the first conductivity type formed at a position deeper than a position of the first accumulation region, whose doping concentration is higher than the doping concentration of the drift region. Also, the first accumulation region and the second accumulation region may be formed in the transistor portion.

The first accumulation region and the second accumulation region may also be formed in the diode portion.

The second aspect of the present invention may provide a manufacturing method of an RC-IGBT having a transistor portion and a diode portion, the method including: forming, on the upper surface side of a semiconductor substrate, a drift region of the first conductivity type, a base region of the second conductivity type, a source region of the first conductivity type, and two or more trench portions passing through the source region and the base region; forming, in the diode portion, a contact trench between two trench portions on the upper surface side of the semiconductor substrate; and forming, in the diode portion, a contact layer of the second conductivity type below a contact trench, whose doping concentration is higher than a doping concentration of the base region.

It may further include: forming, in the transistor portion, a contact trench between two trench portions on the upper surface side of the semiconductor substrate; and forming, in the transistor portion, a contact layer of the second conductivity type below the contact trench. Also, the contact layer of the transistor portion may be formed by implanting ion in two steps, and the contact layer of the diode portion may be formed by implanting ion in one step.

The summary clause does not necessarily describe all necessary features of the embodiments of the present invention. The present invention may also be a sub-combination of the features described above.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a plan view illustrating one example of a semiconductor device 100 according to Example 1.

FIG. 1B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 1.

FIG. 2 illustrates one example of an enlarged view in the vicinity of a contact layer 28.

FIG. 3 illustrates examples of doping concentration distributions in the vicinity of the contact layer 28.

FIG. 4 illustrates a more concrete example of a structure of a semiconductor device 100.

FIG. 5A is a plan view illustrating one example of a semiconductor device 500 according to Comparative Example 1.

FIG. 5B illustrates one example of the cross-section a-a′ of the semiconductor device 500 according to Comparative Example 1.

FIG. 5C illustrates one example of the cross-section b-b′ of the semiconductor device 500 according to Comparative Example 1.

FIG. 6 is a graph illustrating built-in potentials ΔV_(bi) of Example 1 and Comparative Examples 2 and 3.

FIG. 7A is a plan view illustrating one example of a semiconductor device 100 according to Example 2.

FIG. 7B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 2.

FIG. 7C illustrates one example of the cross-section b-b′ of the semiconductor device 100 according to Example 2.

FIG. 8 illustrates one example of configuration of a semiconductor device 100 according to Example 3.

FIG. 9 illustrates one example of a manufacturing method of a semiconductor device 100.

FIG. 10A is a plan view to illustrate one example of a semiconductor device 100 according to Example 4.

FIG. 10B illustrates one example of the cross-section a-a′ of a semiconductor device 100 according to Example 4.

FIG. 11 illustrates a more concrete example of a structure of the semiconductor device 100 according to Example 4.

FIG. 12 illustrates one example of the cross-section a-a′ of a semiconductor device 100 according to Example 5.

FIG. 13 illustrates a more concrete example of a structure of the semiconductor device 100 according to Example 5.

FIG. 14A is a plan view illustrating one example of a semiconductor device 100 according to Example 6.

FIG. 14B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 6.

FIG. 15A is a plan view illustrating one example of a semiconductor device 100 according to Example 7.

FIG. 15B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 7.

DESCRIPTION OF EXEMPLARY EMBODIMENTS

Hereinafter, the present invention will be described through embodiments of the invention. However, the following embodiments shall not limit the claimed invention. Also, not all combinations of features described in the embodiments are essential for means to solve problems provided by aspects of the invention.

Example 1

FIG. 1A is a plan view illustrating one example of a semiconductor device 100 according to Example 1. FIG. 1B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 1. The semiconductor device 100 of the present example is a semiconductor chip having a transistor portion 70 including a transistor such as an IGBT (Insulated Gate Bipolar Transistor), and a diode portion 80 including a diode such as a FWD (Free Wheel Diode). In FIG. 1A, a chip surface in the vicinity of a chip end portion is shown and other regions are omitted.

Note that, in the present specification, one side is referred to as “upper”, and the other side is referred to as “lower” in a direction parallel to a depth direction of a semiconductor substrate 10. The phrases “upper” and “lower” may not be limited by directions of the gravity direction. A direction connecting an emitter electrode and a collector electrode is referred to as the depth direction. Also, in each embodiment, an example is shown in which the first conductivity type and the second conductivity type are of an N type and a P type respectively. However, conductivity types of a substrate, layer, region, or the like may be of inverse polarity respectively.

The semiconductor device 100 of the present example has source regions 12, contact regions 15, a well region 17, contact trenches 27, dummy trench portions 30, gate trench portions 40, a gate metal layer 50, an emitter electrode 52, contact holes 55, 56, and 57, and emitter trench portions 60, on a chip upper surface side. Note that, in the present specification, if simply calling trench portions, they refer to the dummy trench portions 30, the gate trench portions 40, and the emitter trench portions 60.

The semiconductor substrate 10 is a substrate formed of a silicon semiconductor or the like. The semiconductor substrate 10 may also be formed of a compound semiconductor such as a silicon carbide semiconductor or a gallium nitride semiconductor. The semiconductor substrate 10 of the present example is of an N+ type. The semiconductor substrate 10 includes source regions 12, base regions 14, contact regions 15, accumulation regions 16, a well region 17, a drift region 18, a buffer region 20, a collector region 22, and a cathode region 82. Also, the gate metal layer 50 and the emitter electrode 52 are formed on the upper surface, and a collector electrode 24 is formed on the lower surface, of the semiconductor substrate 10. An interlayer dielectric film is formed between the emitter electrode 52 and the gate metal layer 50, and the upper surface of the semiconductor substrate 10. However, it is omitted from the drawing of the present example.

The drift region 18 is formed on the upper surface side of the semiconductor substrate 10. The upper surface side of the semiconductor substrate 10 may refer to above the upper surface of the semiconductor substrate 10, or may refer to the vicinity of the upper surface inside the semiconductor substrate 10. The drift region 18 is formed on back surface sides of the accumulation regions 16. The drift region 18 of the present example is of an N− type.

The base regions 14 are formed above the drift region 18. The base regions 14 may be formed by implanting dopants from the upper surface side of the drift region 18. The base regions 14 are respectively formed in mesa portions sandwiched by the trench portions. The mesa portions refer to regions between adjacent trench portions. The base regions 14 have doping concentrations lower than a doping concentration of the well region 17. The base regions 14 of the present example are of P− types.

The source regions 12 are formed above the base regions 14. Also, the source regions 12 are formed extending in extending directions of the trench portions. The source regions 12 of the present example are formed in mesa portions between two adjacent trench portions among a plurality of trench portions. The source regions 12 may be formed by implanting dopants from the upper surface sides of the base regions 14. The source regions 12 of the present example are of N+ types. Note that, in the present specification, the Y axis direction is an extending direction of a trench portion, and the X axis direction is an arrangement direction of the trench portion. The Z axis direction is a depth direction of the semiconductor device 100.

The contact trenches 27 are formed on the upper surface side of the semiconductor substrate 10. The contact trenches 27 are formed between adjacent trench portions, and provided in direct contact with the source regions 12. In one example, the contact trenches 27 are formed by etching the source regions 12. Conductive materials may be embedded in the contact trenches 27 in the same process as a process of embedding conductive materials to the emitter electrode 52.

Contact layers 28 are provided below the contact trenches 27. Also, each contact layer 28 is formed between two trench portions so as to extend in the extending direction of the two trench portions. The contact layers 28 may be formed by implanting dopants via the contact trenches 27. For example, the contact layers 28 are formed by implanting boron (B) or boron fluoride (BF₂). The contact layers 28 may be formed by implanting two or more types of dopants in two or more steps. The contact layers 28 of the present example are of P+ types. The contact layers 28 suppress latch-ups by extracting holes.

Also, peaks of a doping concentration in the contact layers 28 are positioned shallower than positions of the lower ends of the source regions 12. That is, peaks of a doping concentration in the contact layers 28 of the present example are formed away from side walls of the base regions 14 in which the threshold voltage Vth is decided. Thereby, even if miniaturized, the contact layers 28 of the present example have a small influence on the threshold voltage Vth. Also, each contact layer 28 may have a plurality of peaks of a doping concentration. Preferably, the maximum peak among a plurality of peaks in a contact layer 28 is positioned shallower than a position of the lower end of a source region 12.

The buffer region 20 is formed on the back surface side of the drift region 18. A doping concentration of the buffer region 20 is higher than a doping concentration of the drift region 18. Depletion layers expanding from the back surface sides of the base regions 14. The buffer region 20 functions as a field stop layer to prevent the depletion layers from reaching the collector region 22 and the cathode region 82. The buffer region 20 of the present example is of an N− type.

The contact regions 15 are formed above the base regions 14. The contact regions 15 have doping concentrations higher than the doping concentrations of the base regions 14. The contact regions 15 may be formed by implanting dopants from the upper surface sides of the base regions 14. The contact regions 15 of the present example are of P+ types.

The accumulation regions 16 are formed between the drift region 18 and the base regions 14. The accumulation regions 16 are formed to have concentrations higher than a doping concentration of the semiconductor substrate 10. Also, the doping concentrations of the accumulation regions 16 are higher than the doping concentration of the drift region 18. In one example, the doping concentrations of the accumulation regions 16 are from 1E16 cm⁻³ to 1E18 cm⁻³ inclusive. For example, the accumulation regions 16 are formed by implanting N type dopants such as phosphorous from the upper surface side of the semiconductor substrate 10. Note that, the E means 10 to the power of, for example, 1E16 cm⁻³ means 1×10¹⁶ cm⁻³.

Also, each accumulation region 16 is formed between adjacent trench portions. For example, an accumulation region 16 is formed between a dummy trench portion 30 and a gate trench portion 40 in the transistor portion 70. The accumulation region 16 may be provided such that it covers the entire region between the dummy trench portion 30 and the gate trench portion 40. By providing the accumulation region 16, holes implanted from the collector region 22 to the drift region 18 are suppressed from flowing into the base region 14 in an ON state. Thereby, implanting electrons from the source region 12 to the base region 14 is facilitated. Thereby, the ON voltage of the semiconductor device 100 is reduced.

However, if a semiconductor device 100 has accumulation regions 16, carrier density rises by carrier Injection-Enhancement (IE) effect, and latch-ups are prone to occur. In the semiconductor device 100 of the present example, holes are extracted by the contact layers 28 at a time of turn-off. Thereby, it is possible to suppress latch-ups. Therefore, in the semiconductor device 100, it is possible to reduce the ON voltage as well as to suppress latch-ups.

The collector region 22 is formed on the back surface side of the buffer region 20 in the transistor portion 70. The cathode region 82 is formed on the back surface side of the buffer region 20 in the diode portion 80. Also, the back surfaces of the collector region 22 and the cathode region 82 are provided with the collector electrode 24. The collector electrode 24 is formed of a metal material such as aluminum, gold, or silver.

The contact holes 55, 56, and 57 are formed, passing through the interlayer dielectric film formed above the semiconductor substrate 10. The contact hole 55 connects the gate metal layer 50 and a gate conductive portion 44. The contact holes 56 connect the emitter electrode 52 and dummy conductive portions 34. The contact hole 57 connects the emitter electrode 52 and an emitter conductive portion 64. Positions to form the contact holes 55, 56, and 57 are not particularly limited to those in the present example.

The emitter electrode 52 contacts the semiconductor substrate 10 through the contact holes 56 and 57. The emitter electrode 52 is formed of a material containing metal. In one example, at least a part of a region of the emitter electrode 52 is formed of aluminum. The emitter electrode 52 may have a region formed of a material containing tungsten.

The gate metal layer 50 contacts the semiconductor substrate through the contact hole 55. The gate metal layer 50 is formed of a material containing metal. In one example, at least a part of a region of the gate metal layer 50 is formed of aluminum. The gate metal layer 50 may have a region formed of a material containing tungsten. The gate metal layer 50 of the present example is formed of the same material as a material of the emitter electrode 52. However, the gate metal layer 50 may be formed of a material different from the material of the emitter electrode 52.

Two or more gate trench portions 40, two or more dummy trench portions 30, and two or more emitter trench portions 60 are formed on the upper surface side of the semiconductor substrate 10. The order of arrangement of the trench portions is not limited to that of the present example.

The dummy trench portions 30 and the gate trench portions 40 are formed from the upper end sides of the source regions 12, passing through the source regions 12, the base regions 14, and the accumulation regions 16. Also, the dummy trench portions 30 and the gate trench portions 40 are formed extending in predetermined extending directions on the upper surface of the semiconductor substrate 10. One or more dummy trench portions 30 are arranged along a predetermined arrangement direction while leaving a predetermined gap from the gate trench portions 40 in a region of the transistor portion 70. The dummy trench portions 30 and the gate trench portions 40 of the present example are formed extending in a direction perpendicular to the arrangement direction. The dummy trench portions 30 and the gate trench portions 40 may have loop shapes at their ends in extending directions, respectively.

The gate trench portions 40 and the dummy trench portions 30 of the present example are alternately arranged in a predetermined arrangement direction. Also, the trench portions may be arranged leaving a regular gap from each other. However, arrangement of each trench is not limited to the above-mentioned example. A plurality of gate trench portions 40 may be arranged between two dummy trench portions 30. Also, each number of gate trench portions 40 provided between dummy trench portions 30 may not be constant.

The emitter trench portions 60 are formed from the upper end sides of the source regions 12, passing through the source regions 12, the base regions 14, and the accumulation regions 16. The emitter trench portions 60 are provided in a region of the diode portion 80. The emitter trench portions 60 are formed extending in predetermined extending directions on the upper surface of the semiconductor substrate 10. A gap between emitter trench portions 60 of the present example may match a gap between a dummy trench portion 30 and a gate trench portion 40, but this is not essential. Note that, a P+ type well region 17 is formed at ends in the extending directions of the dummy trench portions 30, the gate trench portions 40, and the emitter trench portions 60.

The gate trench portions 40 have dielectric films 42 and gate conductive portions 44 formed on the upper surface side of the semiconductor substrate 10. The gate conductive portions 44 at least include a region facing an adjacent base region 14. If predetermined voltages are applied to the gate conductive portions 44 via the gate metal layer 50, channels are formed in the base region 14, at a shallow portion over the gate trench portions 40. The gate conductive portions 44 of the present example are formed of conductive materials such as polysilicon. The gate conductive portions 44 are one example of trench conductive portions. The dielectric films 42 may be formed by oxidizing or nitriding semiconductors at the inner walls of gate trenches so as to cover the surrounding of the gate conductive portions 44.

The dummy trench portions 30 have dielectric films 32 and the dummy conductive portions 34 which are formed on the upper surface side of the semiconductor substrate 10. The dummy conductive portions 34 may be formed of the same materials as materials of the gate conductive portions 44. For example, the dummy conductive portions 34 are formed of conductive materials such as polysilicon. The dummy conductive portions 34 are one example of trench conductive portions. The dielectric films 32 may be formed by oxidizing or nitriding semiconductors at the inner wall of dummy trenches so as to cover the surrounding of the dummy conductive portions 34.

The diode portion 80 is provided in a region in direct contact with the transistor portion 70. The diode portion 80 has base regions 14, accumulation regions 16, a drift region 18, and a buffer region 20 that are similar to those of the transistor portion 70 at the same level. The cathode region 82 is provided on the back surface side of the buffer region 20 in the diode portion 80. Note that, in the present specification, a region of the lower surface, which corresponds to the cathode region 82 in an active region, is taken as the diode portion 80. Alternatively, a projection region on which the cathode region 82 is projected may be taken as the diode portion 80, when the cathode region 82 is projected on the upper surface of the semiconductor substrate 10 in a direction perpendicular to the lower surface of the semiconductor substrate 10. Also, in an active region, a projection region on which the collector region 22 is projected is taken as the transistor portion 70, when the collector region 22 is projected on the upper surface of the semiconductor substrate 10 in a direction perpendicular to the lower surface of the semiconductor substrate 10. The projection region is also a region in which predetermined unit configurations, each including a source region 12 and a contact region 15, are regularly arranged.

In the diode portion 80, the cathode region 82 may be positioned in a direction away from an outermost contact region 15 in the Y axis direction (the +Y direction in the Y axis direction of FIG. 1A), away from a boundary position between a source region 12 and the contact region 15 on the upper surface of the semiconductor substrate 10. Also, the cathode region 82 may be positioned in a direction away from an end of a contact trench 27 in the Y axis direction (the +Y direction in the Y axis direction of FIG. 1A), away from the end. Thereby, it is possible to suppress excessive implantation of holes from the contact regions 15.

The emitter trench portions 60 are formed, reaching the drift region 18 from the upper surface sides of the base regions 14, passing through the base regions 14 and the accumulation regions 16. Each emitter trench portion 60 includes a dielectric film 62 and an emitter conductive portion 64. Dielectric films 62 may be formed by oxidizing or nitriding semiconductors at the inner walls of emitter trenches so as to cover the surrounding of emitter conductive portions 64.

FIG. 2 illustrates one example of an enlarged view in the vicinity of a contact layer 28. The present example shows a mesa portion between a dummy trench portion 30 and a gate trench portion 40. However, any mesa portions between a pair of portions which are any two among the dummy trench portions 30, the gate trench portions 40, and the emitter trench portions 60 may have the same structure as a structure of the mesa portion in the present example.

A mesa width W_(M) represents a width of a mesa portion in the X axis direction. The mesa width W_(M) of the present example is a mesa width of the mesa portion between the dummy trench portion 30 and the gate trench portion 40. The mesa width W_(M) of the present example is 0.7 μm.

A hole extraction width W_(H) is a width of the lower end of a source region 12 in the X axis direction. That is, the hole extraction width W_(H) is a distance from a side wall of a trench portion to a contact layer 28. The hole extraction width W_(H) corresponds to the distance of holes to flow from the side wall of the trench portion through which the holes have passed to the contact layer 28. Shortening the hole extraction width W_(H) lowers a resistance value of a path for extracting the holes. Thereby, it becomes easy to extract the holes at a time of turn-off. If it becomes easy to extract the holes, it is difficult for a parasitic NPN transistor to operate. Thereby, latch-ups are suppressed.

In one example, the hole extraction width W_(H) measures from 10% to 30% inclusive of the mesa width W_(M). If two source regions 12 are formed between adjacent trench portions like those in the present example, the hole extraction width W_(H) represents a width of the lower end of any one of the source regions 12. That is, if source regions 12 are formed at both ends of a mesa respectively, the hole extraction width W_(H) accounts for 20 to 60% inclusive of the mesa width W_(M). For example, the hole extraction width W_(H) is from 0.05 μm to 0.25 μm inclusive. The hole extraction width W_(H) of the present example is 0.1 μm.

A contact width W_(C) is a width of a region in the mesa width W_(M) in the X axis direction excluding the hole extraction width W_(H). That is, the contact width W_(C) represents a width of a contact layer 28 in the X axis direction, at the same depth as a position of the lower end of a source region 12. In one example, the contact width W_(C) accounts for 40 to 80% inclusive of the mesa width W_(M). For example, the contact width W_(C) is from 0.2 μm to 0.6 μm inclusive. The contact width W_(C) of the present example is 0.5 μm.

A contact trench width W_(CT) is a width of a contact trench 27 in the X axis direction. In one example, the contact trench width W_(CT) is from 0.1 μm to 0.4 μm inclusive. The contact trench width W_(CT) of the present example is 0.3 μm. Also, a depth D2 of the contact trench 27 is 0.3 μm from the upper end of the semiconductor substrate 10. The contact trench width W_(CT) and the depth D2 may be decided depending on a required contact resistance. Also, the contact trench width W_(CT) may be decided depending on the size of a contact layer 28 that is formed by implanting ion over a contact trench 27.

The lower end of a source region 12 is positioned deeper than a position of the lower end of a contact trench 27. In addition, a peak of a doping concentration of the contact layer 28 is formed at a position shallower than the position of the lower end of the source region 12. Thereby, even if miniaturized, contact layers 28 have a small influence on the threshold voltage Vth. Note that, the lower end of the source region 12 is positioned deeper than positions of upper ends of a dummy conductive portion 34 and a gate conductive portion 44. A depth D1 of the lower end of a source region 12 of the present example is 0.45 μm from the upper end of the semiconductor substrate 10.

The upper end of a contact layer 28 is positioned shallower than the position of the lower end of the source region 12. Also, the lower end of the contact layer 28 is positioned deeper than the position of the lower end of the source region 12. Forming a thick contact layer 28 makes holes likely to be extracted. Thereby, latch-ups are likely to be suppressed. In one example, the lower end of the contact layer 28 may be positioned as deep as the position of the lower end of a base region 14. In this case, because the lower end of the contact layer 28 is distanced from the source region 12, a hole extraction effect becomes more significant. For example, a thickness D3 in a depth direction of the contact layer 28 is from 0.1 μm to 1.0 μm inclusive. A thickness D3 in a depth direction of the contact layer 28 of the present example is 0.5 μm.

Note that, the contact layer 28 may be formed such that the lower end of the contact layer 28 is positioned shallower than a position half the thickness of the base region 14. Forming a shallow contact layer 28 allows the number of times to implant ions for forming the contact layer 28 to be reduced. Thus, a cost of manufacturing semiconductor devices 100 is reduced.

Also, below a contact trench 27, a doping concentration of a contact layer 28 may be larger than a doping concentration of a source region 12 at the same depth. That is, a region below the contact trench 27 is a region in which an N+ type source region 12 has changed into a P+ type contact layer 28 by implanting a high concentration dopant. Note that, the point O and the point O′ refer to origins of a graph of doping concentrations illustrated in FIG. 3 respectively.

FIG. 3 illustrates examples of doping concentration distributions in the vicinity of the contact layer 28. The vertical axis represents the doping concentration, and the horizontal axis represents the distance in the depth direction from the lower end of the contact trench 27. The solid line represents doping concentrations of the contact layer 28 and the base region 14 observed in the depth direction from the point O. The dashed line represents a doping concentration of the source region 12 observed in the depth direction from the point O′. That is, the graph of the doping concentration distributions of the present example displays doping concentrations in the depth directions from two different points O and O′ respectively, in an overlapping manner. The depth of the point O and the depth of the point O′ correspond to a depth of the lower end of the contact trench 27.

The source region 12 is formed by ion implanting arsenic (As) from the upper surface side of the base region 14. The doping concentration of the source region 12 is approximately 1E18 cm⁻³ at the point O′ of the lower end of the contact trench 27.

The contact layer 28 is formed by ion implanting boron fluoride and boron over the contact trench 27 in two steps. The first peak P1 of the contact layer 28 is approximately 1E20 cm⁻³. The first peak P1 of the contact layer 28 is formed at a position shallower than a position of the lower end of the source region 12. The second peak P2 of the present example is formed at a position deeper than the position of the lower end of the source region 12. However, the second peak P2 may be formed at a position shallower than the position of the lower end of the source region 12.

Also, the contact layer 28 may have three or more peaks. In this case, all of the peaks may be formed at a position shallower than the position of the lower end of the source region 12, or a part of the peaks may be formed at a position deeper than the position of the lower end of the source region 12. That is, it is sufficient if at least one of the peaks of the doping concentration of the contact layer 28 is formed at a position shallower than the position of the lower end of the source region 12. Also, among the peaks of the doping concentration of the contact layer 28, the maximum peak may be formed at a position shallower than the position of the lower end of the source region 12.

Note that, the distributions of the doping concentrations of the present example is merely one example. To realize the semiconductor device 100 disclosed in the present specification, the number of the peaks, the depth, or the like may be changed appropriately.

FIG. 4 illustrates a more concrete example of a structure of a semiconductor device 100. In the present example, an interlayer dielectric film 26 is not omitted from the drawing.

The interlayer dielectric film 26 is formed above the semiconductor substrate 10. The interlayer dielectric film 26 of the present example is a BPSG (Boron Phosphorus Silicon Glass) film. The interlayer dielectric film 26 may have a plurality of layers formed of different materials. In a layer with a thickness D1 from the upper end of the source region 12, the interlayer dielectric film 26 has the lower end opening of which width is W1 and the upper end opening of which width is W2.

A contact trench 27 is tapered. A contact trench 27 of the present example is tapered such that its width of the upper end is larger than its width of the lower end. The tapered contact trench 27 facilitates implanting dopants in side walls of the contact trench 27.

A contact layer 28 is formed over the tapered contact trench 27. Thereby, the contact layer 28 is formed on at least parts of side walls of the contact trench 27. For example, a contact layer 28 of the present example is formed upwardly extending in direct contact with side walls of the contact trench 27 from the lower end of the contact trench 27. Also, a contact width W_(C) changes depending on an opening width W2 at the lower end of a BPSG film. That is, a hole extraction width W_(H) also changes depending on the opening width W2 at the lower end of the BPSG film. In the present example, an opening width W1 at the upper end of the BPSG film is 0.45 μm, and an opening width W2 at the lower end of the BPSG film is 0.3 μm.

Also, a contact layer 28 may be formed in direct contact with an accumulation region 16. In this case, L1=L2. The distance L1 represents a distance in a depth direction between the lower end of a source region 12 and the upper end of an accumulation region 16. The distance L2 represents a distance in a depth direction between the lower end of a source region 12 and the lower end of a contact layer 28. Also, the lower end of the contact layer 28 may be provided at a position deeper than half the distance between the upper end of the accumulation region 16 and the lower end of the source region 12. In this case, L1/2<L2.

Note that, a multi-layered film may be formed as an emitter electrode 52 on the contact trench 27 and an opened interlayer dielectric film 26. In one example, the emitter electrode 52 may have a structure in which titanium/titanium nitride (Ti/TiN), tungsten, and aluminum are stacked.

Comparative Example 1

FIG. 5A is a plan view illustrating one example of a semiconductor device 500 according to Comparative Example 1. FIG. 5B illustrates one example of the cross-section a-a′ of the semiconductor device 500 according to Comparative Example 1. FIG. 5C illustrates one example of the cross-section b-b′ of the semiconductor device 500 according to Comparative Example 1.

The semiconductor device 500 of the present example does not have contact trenches 27 and contact layers 28. A hole extraction width W_(H0) represents a distance of carriers to flow along a side wall of a trench portion to a contact region 15. In the semiconductor device 500, holes flow through a side wall of a gate trench portion 40 under a source region 12, then flow from the side wall of the gate trench portions 40 to the contact region 15.

Here, the hole extraction width W_(H0) in the extending direction of a trench portion may be wider than a hole extraction width in the arrangement direction of a trench portion. In this case, the hole extraction width W_(H0) of the semiconductor device 500 is wider than a hole extraction width W_(H) of a semiconductor device 100. That is, a hole extraction efficiency is decreased, and suppressing latch-ups in the semiconductor device 500 becomes difficult. Particularly, as miniaturizing progresses, current density in mesa portions rises. Thereby, latch-ups are likely to occur at a time of turn-off in the semiconductor device 500.

FIG. 6 is a graph illustrating built-in potentials ΔV_(bi) of Example 1 and Comparative Examples 2 and 3. The vertical axis represents the relative value of the built-in potential ΔV_(bi), and the horizontal axis represents the relative value of hole extraction widths W_(H), and W_(H0). Illustrated is a case in which Example 1 and Comparative Example 2 have pitches of 1.9 μm. Illustrated is a case in which Comparative Example 3 has a pitch of 2.3 μm. A pitch refers to a distance from a center of a certain trench portion to a center of another trench portion adjacent to the certain trench portion in the arrangement direction. Once a relative value of a built-in potential ΔV_(bi) becomes 2, a latch-up occurs.

The smaller a pitch becomes by miniaturizing, the narrower the hole extraction width W_(H) according to Example 1 becomes. On the other hand, even if a pitch becomes smaller by miniaturizing, the hole extraction widths W_(H0) according to Comparative Examples 2 and 3 do not necessarily become narrower. Therefore, the smaller the pitch becomes by miniaturizing, the relatively narrower the hole extraction width W_(H) becomes as compared with the hole extraction width W_(H0). For example, if the hole extraction width W_(H) according to Example 1 is 1, the hole extraction widths W_(H) of Comparative Examples 2 and 3 are approximately 50% to 170% of the size of the width W_(H) of the Example 1.

Also, in Comparative Examples 2 and 3, if pitches are miniaturized from 2.3 μm to 1.9 μm, the built-in potentials ΔV_(bi) rise. If the built-in potentials ΔV_(bi) rise, latch-ups are likely to occur in semiconductor devices 500. On the other hand, with respect to Example 1, because the hole extraction width W_(H) is short, and holes are likely to be extracted, it is possible to suppress latch-ups even if miniaturizing progresses. If anything, with respect to Example 1, holes are extracted in the arrangement direction. Thereby, the smaller the pitch becomes, the shorter the hole extraction width W_(H) becomes.

Example 2

FIG. 7A is a plan view illustrating one example of a semiconductor device 100 according to Example 2. FIG. 7B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 2. FIG. 7C illustrates one example of the cross-section b-b′ of the semiconductor device 100 according to Example 2. Source regions 12 and contact regions 15 of the present example are alternately provided in the extending directions of trench portions in a transistor portion 70.

The source regions 12 and the contact regions 15 are formed on the upper surface side of a semiconductor substrate 10. Source regions 12 and contact regions 15 are formed from one trench portion to the other adjacent trench portion. Then, a contact trench 27 is formed in the extending direction of a trench portion such that the contact trench 27 transverses the source regions 12 and the contact regions 15. Thereby, the source regions 12 and the contact regions 15 are alternately provided in extending directions of trench portions, along side walls of the trench portions respectively. Note that, in a diode portion 80 of the present example, a source region 12 is formed between adjacent emitter trench portions 60, in a similar manner as forming the source region 12 of the Example 1.

In the diode portion 80, the cathode region 82 may be positioned in a direction away from an outermost contact region 15 in the Y axis direction (the +Y direction in the Y axis direction of FIG. 7A), away from a boundary position between a source region 12 and the contact region 15 on the upper surface of the semiconductor substrate 10. Also, the cathode region 82 may be positioned in a direction away from an end of a contact trench 27 in the Y axis direction (the +Y direction in the Y axis direction of FIG. 7A), away from the end. Thereby, it is possible to suppress excessive holes from being implanted from the contact regions 15.

Similar to the semiconductor device 100 according to Example 1, because the semiconductor device 100 of the present example has contact layers 28 formed below contact trenches 27, it is possible to suppress latch-ups by hole extraction. Also, the source regions 12 and the contact regions 15 are alternately provided in the semiconductor device 100 of the present example. Thereby, a saturation current is suppressed, and thus latch-ups can be further suppressed.

Example 3

FIG. 8 illustrates one example of configuration of a semiconductor device 100 according to Example 3. Contact layers 28 of the present example are formed by implanting dopants in multiple steps. For example, the contact layers 28 are formed through three steps of implantation processes.

Interlayer dielectric films 26 function as masks while dopants are implanted in the contact layers 28. Also, the interlayer dielectric films 26 of the present example are tapered. Therefore, a thickness of an interlayer dielectric film 26 as a mask depends on a dopant implantation position for a contact layer 28. A dopant implantation depth is shallow in a region where an interlayer dielectric film 26 is formed thick. Therefore, for the contact layer 28, a dopant is implanted at a deep position near the center of a contact trench 27, and a dopant is implanted at a shallow position at an end of the contact trench 27.

Thereby, a width of the lower end of the contact layer 28 is narrower than a width of the upper end of the contact layer 28. That is, the contact layer 28 of the present example has a shape that gradually gets narrower from the upper side to the lower side. Here, if a shape of a contact layer 28 has a maximum width somewhere between the upper side and the lower side instead of the shape having the width that gradually gets narrower, there is a risk that electric fields are concentrated at an end of the contact layer 28. On the other hand, the contact layer 28 of the present example has the shape formed to gradually get narrower. Thereby, in a case in which a depletion layer extends, it is difficult for electric fields to be concentrated at an end of the contact layer 28.

FIG. 9 illustrates one example of a manufacturing method of a semiconductor device 100. In the present example, a manufacturing method of the semiconductor device 100 according to Example 3 is particularly described. In the drawing, a cross-sectional view of one cell is illustrated. However, other cells may be formed in the same manner.

First, a semiconductor substrate 10 is prepared. The semiconductor substrate 10 is a silicon substrate having a drift region 18. A doping concentration of the drift region 18 of the present example is from 3.0E+13 cm⁻³ to 2.0E+14 cm⁻³ inclusive, for example. A thickness of the drift region 18 depends on a withstand voltage class of the semiconductor device 100.

Next, in step S300, a source region 12, a base region 14, and gate trench portions 40 are formed on a surface of the semiconductor substrate 10. First, etching masks with predetermined patterns are provided on the surface of the semiconductor substrate 10 to form grooves of the gate trench portions 40. Gate dielectric films are formed at inner walls of the grooves of the gate trench portions 40. Then, gate conductive portions 44 are formed by depositing in the trench portions, polysilicon in which N type dopants are doped at a high concentration. Thereby, the gate trench portions 40 are formed.

Next, an oxide film is formed on the upper surface of the semiconductor substrate 10, in a region in which the base region 14 and the source region 12 are not formed. Then, a P type dopant is selectively implanted from the surface side of the semiconductor substrate 10, and approximately 2 hours of thermal treatment is conducted at a temperature of approximately 1100° C. In this manner, a P− type base region 14 is formed on the entire surface of the semiconductor substrate 10. The P type dopant may be boron. AP type dopant may be doped in the P− type base region 14 at a doping concentration of 2.5E+13 cm⁻². The base region 14 is formed in direct contact with the gate trench portions 40, and regions of which contacting the gate trench portions 40 function as channels.

Next, as an N type dopant for forming the source region 12, arsenic, phosphorous, or the like is ion implanted from the upper surface side of the semiconductor substrate 10. The source region 12 is formed on the entire surface of the region in which the base region 14 is formed. An N type dopant may be doped in the source region 12 at a doping concentration of 5.0E+19 cm⁻². After the ion implantation, thermal treatment or the like is conducted to form the source region 12. The source region 12 is also formed in direct contact with the gate trench portions 40. Next, an interlayer dielectric film 26 is formed on the upper surface of the semiconductor substrate 10 by CVD method.

Next, in step S302, a resist pattern is formed on the upper surface of the interlayer dielectric film 26. The interlayer dielectric film 26 exposed by an opening of the resist pattern is etched by RIE, thus the semiconductor substrate 10 is exposed. Next, the exposed upper surface of the semiconductor substrate 10 is etched to form a contact trench 27 between two trench portions, passing through the interlayer dielectric film 26 and being in direct contact with the source region 12. Also, the contact trench 27 is formed inside the source region 12 that is formed on the entire surface. By forming the contact trench 27 inside the source region 12, if a contact layer 28 is formed in a subsequent process, a peak of the contact layer 28 can be formed at a position shallower than the position of the lower end of the source region 12.

Next, in step S304, a P type dopant such as boron is ion implanted in an implantation region 93 that is in direct contact with the lower end of the contact trench 27. In the present example, acceleration energy of the P type dopant is approximately 30 keV, and a dosage of the P type dopant is from 1.0E+15 cm⁻² to 5.0E+15 cm⁻² inclusive.

Next, a dopant is implanted below the base region 14 from the lower end of the contact trench 27. For example, in order to implant a P type dopant such as boron below the base region 14, ion is perpendicularly implanted from the lower end of the contact trench 27. In this manner, the contact layer 28 is formed in a region facing the lower end of the contact trench 27 such that a peak of a doping concentration of the contact layer 28 is positioned shallower than the position of the lower end of the source region 12. Dopants may be implanted in the contact layer 28, in multiple steps. The step of forming the contact layer 28 of the present example includes a step of implanting the first dopant and a step of implanting the second dopant. For example, boron is implanted as the first dopant and boron fluoride is implanted as the second dopant. Also, in each P type dopant implantation, acceleration energy may be changed depending on the depth of the contact layer 28 to be formed. One or more implantation regions 94 are formed below the implantation region 93 by the P type dopant implantation.

Next, in step S306, the semiconductor device 100 is thermally treated to activate the P type dopants implanted in the implantation region 93 and the implantation region 94. It is preferable to conduct the thermal treatment in a short time in order to avoid excessive diffusion of the P type dopant. As one example, the temperature and the time of the thermal treatment is approximately 950 degrees Celsius and within 30 minutes, respectively.

In this manner, the contact layer 28 is formed. After the step S306, an emitter electrode 52, a collector electrode 24, and the like are formed to complete the semiconductor device 100. Note that, in order to suppress mutual diffusion between the emitter electrode 52 and the semiconductor region, it is preferable to form a barrier metal layer including a titanium film, a titanium nitride film, a tantalum film, a tantalum nitride film, or the like on an inner wall of the contact trench 27. Also, in order to improve flatness of the emitter electrode 52, the contact trench 27 may be filled with tungsten, molybdenum, polysilicon doped with a dopant, or the like before forming the emitter electrode 52.

Example 4

FIG. 10A is a plan view to illustrate one example of a semiconductor device 100 according to Example 4. FIG. 10B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 4. The semiconductor device 100 of the present example has a transistor portion 70 and a diode portion 80 of which mesa portions have structures different from each other.

The transistor portion 70 includes, on the upper surface side of a semiconductor substrate 10, source regions 12, base regions 14, contact regions 15, accumulation regions 16, contact trenches 27, and contact layers 28. A transistor portion 70 may not have an accumulation region 16 at an end on the side close to its boundary with a diode portion 80. Also, the transistor portion 70 may not have source regions 12 at the end on the side close to its boundary with a diode portion 80. The transistor portion 70 of the present example does not have an accumulation region 16 in the first mesa portion from the end on the side close to its boundary with the diode portion 80, and does not have source regions 12 in the first and the second mesa portions from the end on the side close to the boundary with the diode portion 80. However, a transistor portion 70 may have an accumulation region 16 and source regions 12 in mesa portions on the side close to its boundary with a diode portion 80.

A diode portion 80 is provided in a region in direct contact with a transistor portion 70. The diode portion 80 of the present example includes, on the upper surface side of the semiconductor substrate 10, source regions 12, base regions 14, contact regions 15, contact trenches 27, and contact layers 28.

Contact trenches 27 are formed in regions of any of a transistor portion 70 and a diode portion 80. In the present example, the transistor portion 70 and the diode portion 80 have the contact trenches 27 having structures different from each other. However, a transistor portion 70 and a diode portion 80 may have contact trenches 27 having the same structures.

In one example, widths of contact trenches 27 in a diode portion 80 are narrower than widths of contact trenches 27 in a transistor portion 70. If a diode portion 80 and a transistor portion 70 have contact trenches 27 having equal depths, contact trenches 27 of the diode portion 80 have aspect ratios higher than aspect ratios of contact trenches 27 of the transistor portion 70. In this case, regions in which ions are implanted for forming contact layers 28 are narrow. Thereby, widths of contact layers 28 of the diode portion 80 are narrower than widths of contact layers 28 of the transistor portion 70. That is, in the transistor portion 70, the widths of the contact layers 28 are wide, thus latch-ups are likely to be suppressed at a time of turn-off. Also, in the diode portion 80, the widths of the contact layers 28 are narrow, thus the total amount of doping concentrations of the contact layers 28 in the diode portion 80 is decreased. Thereby, a reverse recovery characteristic is improved.

Contact layers 28 are formed in regions of any of a transistor portion 70 and a diode portion 80. In the present example, the transistor portion 70 and the diode portion 80 have the contact layers 28 having structures different from each other. Even if a transistor portion 70 and a diode portion 80 have contact trenches 27 having the same structures, by changing the number of times of ion implantation of dopants, or the like, the transistor portion 70 and the diode portion 80 may have contact layers 28 having structures different from each other.

In one example, the lower ends of contact layers 28 of a diode portion 80 are positioned shallower than positions of the lower ends of source regions 12. In the diode portion 80, it is preferable to form the contact layers 28 at shallower positions to improve a reverse recovery characteristic. On the other hand, the lower ends of contact layers 28 of a transistor portion 70 may be positioned deeper than positions of the lower ends of the source regions 12. In the transistor portion 70, it is preferable to form the contact layers 28 at positions deeper than positions of the source regions 12 to extract holes at a time of turn-off.

Here, in a semiconductor device 100, a transistor portion 70 and a diode portion 80 may have the same structures. The transistor portion 70 and the diode portion 80 having the same structures indicates that their contact trenches 27 and contact layers 28 are equal in shapes, sizes, doping concentrations, or the like. For example, in this case, in the semiconductor device 100, widths of the contact trenches 27 are set narrow within a range in which latch-ups do not occur in the transistor portion 70. In the semiconductor device 100, depths of the contact trenches 27 may be deep so that their shapes have high aspect ratios.

FIG. 11 illustrates a more concrete example of a structure of the semiconductor device 100 according to Example 4. The drawing illustrates a mesa portion of a transistor portion 70 and a mesa portion of a diode portion 80. The transistor portion 70 and the diode portion 80 have mesa widths W_(M) equal to each other.

Source regions 12 are in direct contact with contact trenches 27. Being in direct contact with the contact trenches 27, the source regions 12 may be electrically connected. For example, if source regions 12 are spaced apart from contact trenches 27, the source regions 12 are in floating state. If source regions 12 are in floating state, the potential is not stabilized and holes may be accumulated. Because the source regions 12 of the present example are in direct contact with the contact trenches 27, it is possible to suppress holes from being accumulated. Note that, the transistor portion 70 and the diode portion 80 have the source regions 12, lower ends of which have equal depths D1.

The transistor portion 70 and the diode portion 80 have contact trenches 27 having the same depths D2. However, a contact trench width W_(CT) of the diode portion 80 is narrower than a contact trench width W_(CT) of the transistor portion 70. That is, in the diode portion 80, widths of the lower ends of the source regions 12 are wide. Here, because latch-ups need to be suppressed in the transistor portion 70 by extracting holes, it is preferable to make widths of the lower ends of the source regions 12 narrow. On the other hand, because the diode portion 80 is free of latch-up problems, there is no need to make widths of the lower ends of the source regions 12 narrow.

The transistor portion 70 and the diode portion 80 have contact layers 28 of which numbers of times of dopant implantations are different from each other. In the present example, the number of times of ion implantation for forming a contact layer 28 of the diode portion 80 is less than the number of times of ion implantation for forming a contact layer 28 of the transistor portion 70. That is, the number of peaks of a doping concentration in the contact layer 28 of the diode portion 80 is less than the number of peaks of a doping concentration in the contact layer 28 of the transistor portion 70. For example, a contact layer 28 in a diode portion 80 has one peak of a doping concentration. On the other hand, a contact layer 28 in a transistor portion 70 has a plurality of peaks of a doping concentration. In the present example, a thickness D3 in the depth direction of the contact layer 28 of the transistor portion 70 is thicker than a thickness D3 of the diode portion 80. That is, the lower ends of the contact layers 28 of the diode portion 80 are positioned shallower than positions of the lower ends of the contact layers 28 of the transistor portion 70.

Also, a doping concentration of a contact layer 28 of a diode portion 80 may be lower than a doping concentration of a contact layer 28 of a transistor portion 70. For example, a doping concentration being lower in a diode portion 80 than in a transistor portion 70 indicates the total amount of dopants implanted in one mesa portion in the diode portion 80 is less than the total amount of dopants implanted in one mesa portion in the transistor portion 70. Alternatively, it may indicate that a concentration of dopants that are ion implanted is lower in the diode portion 80 than in the transistor portion 70.

Thereby, in the diode portion 80, a doping concentration is decreased and a reverse recovery characteristic is improved. Also, in the transistor portion 70, contact layers 28 are formed deeper, thus holes are easily extracted at a time of turn-off. Thereby, it is possible to suppress latch-ups. In the diode portion 80, because latch-ups will not be an issue, there is no need to form contact layers 28 having high doping concentrations.

Also, because the semiconductor device 100 of the present example have N+ type source regions 12 in not only the transistor portion 70 but also the diode portion 80, it is possible to substantially reduce doping concentrations of contact layers 28 in the diode portion 80. Accordingly, in the semiconductor device 100 of the present example, the doping concentrations of the contact layers 28 in the diode portion 80 are even easier to be reduced. In this way, in the semiconductor device 100 of the present example, by individually optimizing the concentrations of the contact layers 28 in the transistor portion 70 and the diode portion 80, latch-ups are suppressed and a reverse recovery characteristic is improved.

Note that, a manufacturing method of the semiconductor device 100 of the present example may be basically conducted in the same flow as the flow of the manufacturing method of the semiconductor device 100 according to Example 3. However, in a case of making a structure of the transistor portion 70 different from a structure of the diode portion 80, different masks may be used for the transistor portion 70 and the diode portion 80. Specifically, if the number of times of ion implantation for forming contact layers 28 in the transistor portion 70 is different from that in the diode portion 80, different masks are used for the transistor portion 70 and the diode portion 80. Thereby, the contact layers 28 of the transistor portion 70 can be formed by implanting ion in two steps, and the contact layers 28 of the diode portion can be formed by implanting ion in one step. In this case, a mask may be used not for implanting ion in the diode portion 80 but only for implanting ion in the transistor portion 70.

FIG. 12 illustrates one example of the cross-section a-a′ of a semiconductor device 100 according to Example 5. The plan view of the semiconductor device 100 of the present example corresponds to the plan view of the semiconductor device 100 according to Example 4 illustrated in FIG. 10A. That is, the cross-section a-a′ of the present example corresponds to the a-a′ cross-section of FIG. 10A.

The semiconductor device 100 of the present example includes, in a transistor portion 70, accumulation regions 16 a and accumulation regions 16 b. However, a transistor portion 70 may not have an accumulation region 16 a at an end on the side close to its boundary with a diode portion 80. On the other hand, the semiconductor device 100 only includes accumulation regions 16 b in the diode portion 80.

Accumulation regions 16 a and accumulation regions 16 b are examples of accumulation regions 16 having depths different from each other. Accumulation regions 16 a are formed at positions shallower than positions of accumulation regions 16 b. Doping concentrations of the accumulation regions 16 a and the accumulation regions 16 b may be the same. Note that, the accumulation regions 16 a are one example of the first accumulation regions. The accumulation regions 16 b are one example of the second accumulation regions.

FIG. 13 illustrates a more concrete example of a structure of the semiconductor device 100 according to Example 5. A transistor portion 70 of the present example is different from the transistor portion 70 in FIG. 12 in that it includes an accumulation region 16 a and an accumulation region 16 b at an end on the side close to its boundary with a diode portion 80. Also, the diode portion 80 is different from the diode portion 80 in FIG. 12 in that it includes accumulation regions 16 a and accumulation regions 16 b.

The lower ends of contact trenches 27 of the diode portion 80 is formed at positions deeper than positions of the lower ends of contact trenches 27 of the transistor portion 70. That is, depths D2 of the contact trenches 27 of the diode portion 80 is larger than depths D2 of the contact trenches 27 of the transistor portion 70. Also, a contact trench width W_(CT) of the diode portion 80 may be shorter than a contact trench width W_(CT) of the transistor portion 70. That is, the contact trenches 27 of the diode portion 80 have aspect ratios higher than aspect ratios of the contact trenches 27 of the transistor portion 70.

Also, contact layers 28 of the diode portion 80 are formed at positions shallower than positions of contact layers 28 of the transistor portion 70. For example, a lower end of a contact layer 28 (that is, D2+D3) of a diode portion 80 is positioned shallower than a position of a lower end of a contact layer 28 of the transistor portion 70. Also, a thickness of a contact layer 28 (that is, D3) of the diode portion 80 is lower than a thickness of a contact layer 28 of the transistor portion 70.

In the diode portion 80 of the present example, by positioning the contact trenches 27 deeper than positions of the contact trenches 27 of the transistor portion 70, the contact layers 28 can have low concentrations. In this way, if the contact layers 28 have low concentrations because the contact trenches 27 of the diode portion 80 are positioned deep, the contact layers 28 are unlikely to be converted into N types. In the semiconductor device 100 of the present example, by making the contact layers 28 of the diode portion 80 have low concentrations, it is possible to improve a reverse recovery characteristic. Note that, the transistor portion 70 and the diode portion 80 have source regions 12, lower ends of which may have the same depths D1. Also, the transistor portion 70 and the diode portion 80 may have equal mesa widths W_(M).

FIG. 14A is a plan view illustrating one example of a semiconductor device 100 according to Example 6. Arrangement of contact trenches 27 in the semiconductor device 100 of the present example is different from that of the semiconductor device 100 according to Example 1.

Ends in the Y axis direction of the contact trenches 27 of the present example are provided inside contact regions 15 in the plan view. That is, the contact trenches 27 are provided extending to reach inside the contact regions 15 from source regions 12 in the plan view. Also, the ends in the Y axis direction of contact trenches 27 may be provided in direct contact with the contact regions 15. The contact trenches 27 of the present example can easily extract external carriers at the ends in the Y axis direction. Thereby, turn-off withstand capability and reverse recovery withstand capability of the semiconductor device 100 are improved.

Also, a transistor portion 70 of the present example has a mesa portion provided on the side closest to a diode portion 80, in which a source region 12 is not formed on the front surface of a semiconductor substrate 10. However, the transistor portion 70 may have a mesa portion provided on the side closest to a diode portion 80, in which a source region 12 is formed.

FIG. 14B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 6. Arrangement method of contact layers 28 in the semiconductor device 100 of the present example is different from that of the semiconductor device 100 according to Example 1. In the semiconductor device 100 of the present example, arrangement of contact layers 28 in the transistor portion 70 varies from contact layers 28 in the diode portion 80.

For example, the semiconductor device 100 of the present example has the transistor portion 70 and the diode portion 80 having contact layers 28. The contact layers 28 of the diode portion 80 may be formed at positions shallower than positions of the contact layers 28 of the transistor portion 70, and may have doping concentrations lower than doping concentrations of the contact layers 28 of the transistor portion 70. In this case, in the diode portion 80, the first peak P1 of a contact layer 28, and a base region 14 may be in direct contact with the bottom surface of a contact trench 27. Thereby, it is possible to suppress excessive holes from being implanted from the contact regions 15.

FIG. 15A is a plan view illustrating one example of a semiconductor device 100 according to Example 7. Arrangement of contact trenches 27 in the semiconductor device 100 of the present example is different from that of the semiconductor device 100 according to Example 2.

Ends in the Y axis direction of the contact trenches 27 of the present example are provided inside contact regions 15 in the plan view. That is, the contact trenches 27 are provided extending to reach inside the contact regions 15 from source regions 12 in the plan view. Also, the ends in the Y axis direction of contact trenches 27 may be provided in direct contact with the contact regions 15. The contact trenches 27 of the present example can easily extract external carriers at the ends in the Y axis direction. Thereby, turn-off withstand capability and reverse recovery withstand capability of the semiconductor device 100 are improved.

Also, a transistor portion 70 of the present example has a mesa portion provided on the side closest to a diode portion 80, in which a source region 12 is not formed on the front surface of a semiconductor substrate 10. However, the transistor portion 70 may have a mesa portion provided on the side closest to a diode portion 80, in which a source region 12 is formed.

FIG. 15B illustrates one example of the cross-section a-a′ of the semiconductor device 100 according to Example 7. Arrangement method of contact layers 28 in the semiconductor device 100 of the present example is different from that of the semiconductor device 100 according to Example 2. In the semiconductor device 100 of the present example, arrangement of contact layers 28 in the transistor portion 70 varies from contact layers 28 in the diode portion 80.

For example, the semiconductor device 100 of the present example has the transistor portion 70 and the diode portion 80 having contact layers 28. The contact layers 28 of the diode portion 80 may be formed at positions shallower than positions of the contact layers 28 of the transistor portion 70, and may have doping concentrations lower than doping concentrations of the contact layers 28 of the transistor portion 70. In this case, in the diode portion 80, the first peak P1 of a contact layer 28, and a base region 14 may be in direct contact with the bottom surface of a contact trench 27. Thereby, it is possible to suppress excessive holes from being implanted from the contact regions 15.

As described above, in the semiconductor device 100 according to the present specification, by forming the source regions 12, contact trenches 27, and contact layers 28 in the diode portion 80, a reverse recovery characteristic of the diode portion 80 is improved. Also, in the semiconductor device 100 of the present example, by forming the contact trenches 27 and contact layers 28 in the transistor portion 70, latch-ups are suppressed. In this way, in the semiconductor device 100 according to the present specification, it is possible to form the transistor portion 70 to suppress latch-ups, and the diode portion 80 with excellent reverse recovery characteristic through a common process.

While the embodiments of the present invention have been described, the technical scope of the present invention is not limited to the above described embodiments. It is apparent to persons skilled in the art that various alterations and improvements can be added to the above-described embodiments. It is also apparent from the scope of the claims that the embodiments added with such alterations or improvements can be included in the technical scope of the invention.

The operations, procedures, steps, stages, or the like of each process performed by an apparatus and method shown in the claims, specification, or drawings can be performed in any order as long as the order is not indicated by “prior to,” “before,” or the like and as long as the output from a previous process is not used in a later process. Even if the process flow is described using phrases such as “first” or “next” in the claims, embodiments, or diagrams, it does not necessarily mean that the process must be performed in this order. 

What is claimed is:
 1. An RC-IGBT having a transistor portion and a diode portion, the RC-IGBT comprising: a semiconductor substrate; a drift region of a first conductivity type provided on an upper surface side of the semiconductor substrate; a base region of a second conductivity type provided above the drift region; a source region of a first conductivity type provided above the base region; and two or more trench portions provided passing through the source region and the base region from an upper end side of the source region, wherein the diode portion has the source region, a contact trench provided between two adjacent trench portions of the two or more trench portions on an upper surface side of the semiconductor substrate, and a contact layer of a second conductivity type provided below a bottom of the contact trench, whose doping concentration is higher than a doping concentration of the base region, wherein the contact trench is in physical contact with the contact layer.
 2. The RC-IGBT according to claim 1, wherein the source region is in direct contact with the contact trench in the diode portion.
 3. The RC-IGBT having a transistor portion and a diode portion according to claim 1, wherein: a lower end of the contact trench is positioned shallower than a position of a lower end of the source region.
 4. An The RC-IGBT having a transistor portion and a diode portion, the RC-IGBT comprising: a semiconductor substrate; a drift region of a first conductivity type provided on an upper surface side of the semiconductor substrate; a base region of a second conductivity type provided above the drift region; a source region of a first conductivity type provided above the base region; and two or more trench portions provided passing through the source region and the base region from an upper end side of the source region, wherein the diode portion has the source region, a contact trench provided between two adjacent trench portions of the two or more trench portions on an upper surface side of the semiconductor substrate, and a contact layer of a second conductivity type provided below the contact trench, whose doping concentration is higher than a doping concentration of the base region, wherein a lower end of the contact layer is positioned shallower than a position of a lower end of the source region.
 5. An The RC-IGBT having a transistor portion and a diode portion, the RC-IGBT comprising: a semiconductor substrate; a drift region of a first conductivity type provided on an upper surface side of the semiconductor substrate; a base region of a second conductivity type provided above the drift region; a source region of a first conductivity type provided above the base region; and two or more trench portions provided passing through the source region and the base region from an upper end side of the source region, wherein the diode portion has the source region, a contact trench provided between two adjacent trench portions of the two or more trench portions on an upper surface side of the semiconductor substrate, and a contact layer of a second conductivity type provided below the contact trench, whose doping concentration is higher than a doping concentration of the base region, and wherein the transistor portion has a contact trench provided between two adjacent trench portions of the two or more trench portions on an upper surface side of the semiconductor substrate, and a contact layer of a second conductivity type provided below the contact trench of the transistor portion, whose doping concentration is higher than a doping concentration of the base region, wherein a width of the contact trench of the diode portion is narrower than a width of the contact trench of the transistor portion.
 6. The RC-IGBT according to claim 5, wherein the contact trench of the diode portion has an aspect ratio higher than an aspect ratio of the contact trench of the transistor portion.
 7. The RC-IGBT according to claim 5, wherein a lower end of the contact trench of the diode portion is positioned deeper than a position of a lower end of the contact trench of the transistor portion.
 8. The RC-IGBT according to claim 5, wherein a lower end of the contact layer of the diode portion is positioned shallower than a position of a lower end of the contact layer of the transistor portion.
 9. The RC-IGBT according to claim 5, wherein the number of peaks of a doping concentration in the contact layer of the diode portion is less than the number of peaks of a doping concentration in the contact layer of the transistor portion.
 10. The RC-IGBT according to claim 5, wherein a doping concentration of the contact layer of the diode portion is lower than a doping concentration of the contact layer of the transistor portion.
 11. An RC-IGBT having a transistor portion and a diode portion, the RC-IGBT comprising: a semiconductor substrate; a drift region of a first conductivity type provided on an upper surface side of the semiconductor substrate; a base region of a second conductivity type provided above the drift region; a source region of a first conductivity type provided above the base region; two or more trench portions provided passing through the source region and the base region from an upper end side of the source region; a first accumulation region of a first conductivity type having a doping concentration higher than a doping concentration of the drift region; and a second accumulation region of a first conductivity type formed at a position deeper than a position of the first accumulation region, whose doping concentration is higher than a doping concentration of the drift region, wherein the first accumulation region and the second accumulation region are formed in the transistor portion, wherein the diode portion has the source region, a contact trench provided between two adjacent trench portions of the two or more trench portions on an upper surface side of the semiconductor substrate, and a contact layer of a second conductivity type provided below a bottom of the contact trench, whose doping concentration is higher than a doping concentration of the base region, and wherein the contact trench is in physical contact with the contact layer.
 12. The RC-IGBT according to claim 11, wherein the first accumulation region and the second accumulation region are also formed in the diode portion.
 13. A manufacturing method of an RC-IGBT having a transistor portion and a diode portion, the method comprising: forming, on an upper surface side of a semiconductor substrate, a drift region of a first conductivity type, a base region of a second conductivity type, a source region of a first conductivity type, and two or more trench portions passing through the source region and the base region; forming, in the diode portion, a contact trench between two trench portions on the upper surface side of the semiconductor substrate; and forming, in the diode portion, a contact layer of a second conductivity type below a bottom of the contact trench, whose doping concentration is higher than a doping concentration of the base region, wherein the contact trench is in physical contact with the contact layer.
 14. The manufacturing method of an RC-IGBT having a transistor portion and a diode portion according to claim 13, wherein: a lower end of the contact trench is formed to be positioned shallower than a position of a lower end of the source region.
 15. A manufacturing method of the RC-IGBT having a transistor portion and a diode portion, the method comprising: forming, on an upper surface side of a semiconductor substrate, a drift region of a first conductivity type, a base region of a second conductivity type, a source region of a first conductivity type, and two or more trench portions passing through the source region and the base region; forming, in the diode portion, a contact trench between two trench portions on the upper surface side of the semiconductor substrate; forming, in the diode portion, a contact layer of a second conductivity type below the contact trench, whose doping concentration is higher than a doping concentration of the base region; forming, in the transistor portion, a contact trench between two trench portions on the upper surface side of the semiconductor substrate; and forming, in the transistor portion, a contact layer of a second conductivity type below the contact trench, wherein the contact layer of the transistor portion is formed by implanting ion in two steps, and the contact layer of the diode portion is formed by implanting ion in one step. 